FB107 Truck Unloading System Operation Manual for Pro-Face Display

Transcription

1 Revision July 2015

2 TABLE OF CONTENTS 1.0 INTRODUCTION 2.0 SYSTEM COMPONENTS 2.1 FB107 Driver Interface Panel FB Star Printer Proface display 2.2 Configuration PC 2.3 Micro Motion Meter 2.4 Drexelbrook Cut Monitor 2.5 Temperature Transmitter 2.6 Ground Permissive Interlock (GPI) Way Divert Valve 2.8 Inlet ESD Valve 2.9 Air Eliminator 3.0 INSTALLATION 3.1 Overall Skid Unit 3.2 TUS FB107 Panel 4.0 PANEL WIRING 4.1 Power Wiring Fuse Layout Power Problems 4.2 Field Wiring 5.0 CONFIGURATION 5.1 FB Micro Motion 5.3 Proface Display 5.4 Configuration Using Proface Display 5.5 Configuration Using TUSPHD Software 5.6 Configuration Using ROCLINK OPERATION 6.1 Truck Unloading Procedure 6.2 Not in use 6.3 Historical Data 6.4 Meter Proving Page 2 of 77

3 7.0 APPENDIX 7.1 Modbus Access 7.2 Communication Wiring 7.3 Water Cut Calculation 7.4 Not in use 7.5 Autocomp Software Operation 7.6 Soft Points in use 7.7 Troubleshooting 7.8 Not in use 7.9 Air Eliminator 7.10 Not in use 7.11 Data Logger 7.12 System Start Up Procedure 7.13 Volume Calculation Test Case 7.14 Not in use 7.15 Not in use 7.16 Totalized Flow Options Page 3 of 77

4 1.0 INTRODUCTION This document is designed to assist technicians and operators in the operation and maintenance of the Truck Unload Panel. If a problem arises that is not covered within this manual please call Spartan Controls. Spartan Controls offers full service and support of this product. For service and/or assistance please call Spartan Controls, Measurement Instrumentation Service department (780) This manual describes the operation of the Spartan Controls Truck Loading / Unloading system model TUS FB107. The TUS FB107 is designed to measure quantities of fluids trucked in or out of oil batteries. The system provides the user with a display for real time flow rates, flow totals, density, temperature, water cut and unloading time, while the truck is unloading. After the truck is done unloading the system prints out a multi-copy ticket with date, time, trucking company, well LSD, unload time, temperature, water cut, oil and water totals, and total volume. The volumes are corrected to 15 degrees C using methods defined by API Chapter 11.1 (American Petroleum Institute). The basic system consists of an FB107 Truck Unload Interface panel, Micro Motion mass flow meter, Drexelbrook Water Cut Monitor or a Phase Dynamics water cut analyzer. The system uses specially developed software based on the Chevron patented net oil calculation to perform the NOC calculations, and Spartan Controls' patented Density Compensated Water Cut Calculation. The FB107 receives signal inputs from the Micro Motion mass flow meter, Drexelbrook Cut Monitor, Phase Dynamics water cut analyzer and calculates the standard volumes completion of the unload process. The TUS FB107 has the following short term internal database: Locations 200 Trucks 100 Tickets 140 Datalogger Unloads Last 8 loads Datalogger records 250 records The system also has long term ticket and data logging saved to a local flash drive. The basic Truck Unload System is shown below, this is a typical diagram and layout can vary depending on construction and options selected. When used as a Transloader the system unloads directly to rail car. Page 4 of 77

5 Page 5 of 77

6 2.0 SYSTEM COMPONENTS The Spartan Controls TUS FB107 Truck Unloading system uses a FB107 as the central controlling device. The FB107 is connected to the Micro Motion mass flow system through the 2500, 2700 transmitter. The inputs are supplied by modbus or pulse & analog signals. The Micro Motion sensor is installed in the flag position to allow proper operation should gas slugs be present in the flow stream. The Micro Motion sensor connects to the Micro Motion transmitter with a by a 4 wire communication cable. A Drexelbrook cut monitor or Phase Dynamics water cut analyzer is used to improve water cut accuracy. If using the divert option the cut monitor has to be included for improved water cut resolution. This cut monitor measurement is supplied by a 4-20mA analog signal. An optional Ground Permissive Interlock (GPI) can be added to insure the truck is properly grounded for safe unloading. The GPI signal is supplied to the FB107 as a discrete input. An optional 3 way divert valve can be used to divert dry oil directly to the sales oil tank avoiding reprocessing fees. All configuration of the database is completed by either the driver interface or a PC (not supplied with system). The PC can be also be used to extract historical load data and perform diagnostics. After configuration is complete all driver interaction is with the local display interface only. The system will print an unload ticket at the completion of the unload process. Data from the unload is stored in the system for historical data access. The system stores 200 well locations, 100 trucking companies and the last 140 unloads. The system also stores 250 data points from the last 8 unloads for unload data analysis. An overview of the system is shown below. Page 6 of 77

7 2.1 TUS FB107 Panel There are a number of internal components in the FB107 panel. The following information gives a brief overview of all internal components. Page 7 of 77

8 2.1.1 FB107 The FB107 is the main component of the Truck Unload Panel, it provides the processor to run the User C software. All data is received, processed, saved and sent to the printer by the ROC. The ROC also is the I/O interface to the associated field instruments. All data stored in ROC is battery backed to ensure that no data is lost during power outages. The hardware overview is shown below STAR PRINTER The printer is a Star SP500. The maintenance requirements of the printer includes: ribbon replacement, paper replacement, and communication testing. All supplies including 1 or 2 copy paper, and ribbon (purple or black) can be supplied by Spartan Controls. The common parts required are: Printer Paper #RF P Printer Ribbon #RC-300P Double Copy paper Printer Ribbon (purple) Refer to the Troubleshooting section of printer manual for further assistance. Page 8 of 77

9 2.1.3 Pro-Face Display The Pro-Face display is used for driver identification entry and for displaying process information. Page 9 of 77

10 I/O The TUS FB107 can be configured with I/O to the Micro Motion meter or modbus communications. The preferred method is modbus communications. The following illustrates the wiring for both options along with the other I/O requirements: Page 10 of 77

11 2.2 CONFIGURATION PC Database configuration changes and historical data access for the FB107 are made with a standard PC running Spartan Controls TUSPHD software or changes can be made from the Proface display. There are 2 PC programs that can be used to interface to the system: TUSPHD - PC Program for Configuration and Database Management The TUSPHD program was written specifically for the FB107 system. The program runs on Windows operating systems. The program allows for configuration changes, data management and data logging functionality. ROCLINK - PC Program for Configuration of FB107 The ROCLINK program from Emerson runs on Windows operating systems. The program allows for configuration changes of the software, I/O and communications settings. 2.3 MICRO MOTION METER The Micro Motion meter consists of a sensor that goes in the flow line and a transmitter that processes data and provides output signals. The flow sensor used for truck unloading systems is usually a model CMF300. The transmitter can be either an RFT9739 (MVD), 2500 or See below CMF300 RFT The Micro Motion transmitter provides measurement by modbus or a pulse output representing volume flow and analog outputs representing density. Temperature should be provided by a remote mount RTD or temperature transmitter. Once the Micro Motion sensor is installed and the transmitter is working properly, a zero calibration should be performed. The flow meter zeroing offsets any noise or vibration that may cause a flow signal. The offset ensures accurate measurement of "zero flow" through the meter. All initial setup and zero flow calibration of the Micro Motion meter should be performed by a Spartan Controls service technician. Additional details can be located in the Micro Motion instruction manual available. Page 11 of 77

12 2.4 DREXELBROOK CUT MONITOR The Drexelbrook cut monitor is an inline device that measures low concentrations of water in hydrocarbon. The Universal 3 electronics is used to provide digital signal processing of the signal. The cut monitor provides a 4-20mA representing 0-5% water cut to the FB107. The water cut signal from the Drexelbrook is uncorrected for temperature and density effects. The signal is corrected in the FB107 resulting in a fully compensated water cut measurement. The calibration of the cut monitor is based on the density range of incoming liquids. The calibration must be calculated and performed by a Spartan Controls technician. Additional details for Drexelbrook can be located in the instruction manual. 2.5 TEMPERATURE TRANSMITTER An external temperature measurement is required to comply to Directive 17 accuracy requirements. The recommended measurement is by an in line RTD that can be wired directly to the FB107. A temperature transmitter can also be used in place of the RTD and feed into the FB107 by an analog input signal. 2.6 GROUND PERMISSIVE INTERLOCK (GPI) The ground permissive switch prevents trucks from unloading if they are not properly grounded. If the truck is grounded properly continuity is achieved between the two wires at the clamp. This closes a contact and sends the ROC a discrete high signal which allows the driver to proceed with the unload. If the truck is not grounded properly the ROC receives a discrete low and system will not allow proceeding until the clamp is properly secured. The input is normally off and will only start with a properly grounded circuit. The unload process will not he halted if continuity is lost during unloading WAY DIVERT VALVE A 3 way divert valve can be used to divert dry oil to the sales oil tank and reduce reprocessing fees. It is recommended to use a 3 way valve instead of 2 individual valves for safety reasons. Using a 3 way valve will prevent the possibility of blocking the flow incase actuator failure occurs. If flow is blocked the result is generally an oil spill due to over pressuring of the truck hose. The divert valve is controlled by a DO signal from the FB INLET BLOCK VALVE An BLOCK valve can be used to prevent unloading access without proper identification and grounding. The ESD valve is controlled by a DO signal from the FB107. Page 12 of 77

13 2.9 AIR ELIMINATOR An eliminator is required for truck unloading installations per Directive 17 installation guidelines for truck unloading. The air eliminator will reduce or eliminate any gas slugs at the beginning and end of the unloading process. The air eliminator is a small separator that allows liquid to pass through and gas to vent from the top. The gas can be vented to a storage tanks or the vapor recovery system. 3.0 INSTALLATION The following section details the installation of the major hardware components. It is recommended that this section is followed closely to ensure that the system will work as designed. If there are any problems with installing the equipment as shown, or if there are any questions, please contact Spartan Controls MI Dept. at (780) OVERALL SKID UNIT The typical skid unit layout is illustrated as follows. Micro Motion mass flow system consists of two parts, a sensor and a transmitter. The sensor should be installed in the flag position as illustrated below. In some installations the Phase Dynamics and 3 way divert valve are installed optionally. For wiring details please consult the wiring prints supplied by Spartan Controls. The Micro Motion RFT9739 or 2700 transmitter can be mounted in the unloading building or pipe stand mounted near the driver interface box. If using a model 2500 transmitter it should be DIN rail mounted in the unloading panel. Page 13 of 77

14 3.2 FB107 TUS Panel The enclosure is designed for installation in a Class 1 Division 2 location and is rated NEMA 4 so it can be mounted outside. The panel's outer door should remain closed in sub-zero temperatures to maintain proper temperature inside the panel. 4.0 Wiring 4.1 Power Wiring Overview Panel Power Requirement: 120 VAC 15 Amp service The panel requires a 120 VAC source. The following illustrates the overall system wiring for clarification. Item Signal Type Signal Represent Truck Unload Panel Wiring Responsibility Wiring / Power Requirement Power Input Customer 120VAC, 60Hz, single phase (15 amp) Modbus Micro Motion Flow & Density Customer 2 Wire Communication Page 14 of 77

15 Drexelbroo k BS&W Ground Permissive Micro Motion CMF300M Sensor Analog Inputs BS&W Customer 24VDC, 4-20 ma (Sourced by panel) RTD Temperature Customer 3 Wire Input Discrete Input Ground Customer Dry contact SPST Discrete Outputs Permissive ESD Valve Water Alarm Customer (Sourced by panel) Dry contact DPDT, 120VAC or 24VDC (Sourced by panel) Analog Output Water Cut Customer 4-20 ma, I.S. (Sourced by panel) Power Input Customer 120VAC, 60Hz, single phase Power & Customer Communication I.S. Process Measurement s & Diagnostics Hardware dependant 4 wire communication (Sourced by Micro Motion transmitter) Micro Motion Transmitte r Power & Modbus Flow & Density Customer Hardware dependant Modbus communication (Sourced by panel) ESD Valve Power Input Customer 120VAC/24VDC depends on valve selection (Sourced by panel) Page 15 of 77

16 Panel Communication Wiring Overview Field Wiring Overview Page 16 of 77

17 4.2 Field Wiring Note: Micro Motion (Density, Temperature and Volume Flow) wiring may vary depending on transmitter model and mounting location. Consult Spartan Controls for questions. There are 2 standard wiring options used. The preferred method is using the second illustration where the Micro Motion is wired for modbus communications. 5.0 Configuration Technicians use the following programs for system configuration and calibration: PROLINK 2 MMI CONFIGURATION HARTWIN DREXELBROOK CONFIGURATION TUSPHD PC PROGRAM FOR CONFIGURATION OF TUS SOFTWARE ROCLINK PC PROGRAM FOR CONFIGURATION OF FB107 The operator of the system should only require the TUSWIN program for configuration, data access and maintenance. 5.1 Configuration of FB107 The Drexelbrook is always wired to AI-2, AI 2 Slot 0. The Ground Permissive Dry Contacts must be always wired to DI-4, DI 4 Slot 0. If the Meter SFP Landing is set to 0 = Disable Polling then the I/O Assignment from the meter will be: Meter Density in g/cc 4-20 ma wired to AI-1, AI 1 Slot 0. Flow Temperature in Deg C must be wired to RTD input AI-3 AI 1 slot 0 Page 17 of 77

18 Flow Pulses from Meter wired to PI-1, PI 1 Slot 0. If the PhaseDyn SFP Landing is set to 0 then the Phase Dynamics logic is ignored, there are no AINs available for the Phase Dynamics. Polling address s are: MMI modbus polling = 1 PDI modbus polling = 11 Analog Inputs Variable Units Range Scan Period Filter Density g/cc 0 to s 3 Temp Deg C -20 to s 3 Cut Dielectric Calculated 0.5 s 3 Pulse Input (If Used) Variable Units Scan Period Conversion Flow M3/min 1 s 100,000 Port Baud Parity Data Stop Bits LOI None 8 1 COM None 8 1 MMI - PDI DISPLAY or None 8 1 Proface 57,600 OPTION CARD None 8 1 Modbus port COM 2 Printer 9600 None 8 1 NOTE: Set Display Port Owner for ROC/Modbus Slave Page 18 of 77

19 CPU CARD SETTINGS: PID & AGA: Disable all PIDs under the Control tab. Page 19 of 77

20 Disable History Points Page 20 of 77

21 Loading Software: There are 5 programs to download in the FB107. Load software into the ROC by the following steps: 1) Clear All existing user programs 2) Choose and download & start user programs 3) Make sure both programs are Status ON 4) Initialize the database in the ROC through the Pro-Face configuration Page 21 of 77

22 COM Ports: There are 5 COM ports used on the FB107 for truck unloading. LOI Port Used for ROCLINK and TUSWIN COM Port Micro Motion COM 2 Printer 485 Port Optional (Slot 2) Modbus Com to host system Display Port Pro-Face display interface NOTE: Set Display Port Owner for ROC/Modbus Slave Page 22 of 77

23 5.2 Configuration of Micro Motion Note: Even when communicating by modbus units configuration is required. Volume Flow Mass Flow Density Temperature M3/min Kg/min g/cc C Analog Outputs Variable Units Range Dampening Slug Flow Low Low Cut Off Density g/cc 0 to s 0.1g/cc 0 below min density Temp Deg C -20 to s NA NA Pulse Output Variable Units Scaling Volume Flow M3/min 100,000 P/M3 Com Ports Baud Parity Data Stop Bits 19,200 None Configuration of Proface The Proface display has a configuration file that is loaded with the Proface software utility. The configuration software is called GP-Pro EX. The configuration file is provided by Spartan Controls. Page 23 of 77

24 5.4 TUS Software Configuration Using Proface Unit Configuration Menu Operator Menu LOGIN: The CONFIGURATION MENU allows configuration of common options in the system. To access the OPERATOR MENU touch the Spartan Controls logo in the top right corner of the display. This will bring up 3 optional screens to choose from. LOGIN: The 3 screen choices allow for maintenance (configuration changes), reprinting of tickets or alarm menu. Select the left hand maintenance icon. OPERATOR MENU: Select the OPERATOR MENU button. You will see a keyboard menu appear asking for a password. Password is Page 24 of 77

25 OPERATOR MENU: The OPERATOR MENU allows the user to add or edit TRUCKING COMPANIES or WELL LOCATIONS. You can also make basic CONFIGURATION changes, view TOTALS and edit TICKET HEADERS. TRUCKING COMPANIES: Selecting TRUCKING COMPANIES allows access to add, edit or print a list of companies. TRUCKING COMPANIES: To add a new trucking company use the up arrow to an open truck code # then enter the truck company name the SAVE. WELL LOCATIONS: Selecting WELL LOCATIONS allows access to add, edit or print a list of locations. Page 25 of 77

26 WELL LOCATIONS: To add a new well location use the up arrow to access an open well code #. Edit the fields as required then SAVE. Typical well configuration is illustrated. If you expect to have free water or wet oil (>5%) the oil & water densities in the database should be maintained. Consult Spartan Controls for details. CONFIGURATION: Selecting CONFIGURATION allows some operational configuration settings. Consult Spartan Controls before making any changes as they will affect system operation. TOTALS: Selecting TOTALS allows viewing of the last load totals and daily production numbers. TICKET HEADERS: Selecting TICKET HEADERS allows editing of 5 lines of custom ticket messages. Page 26 of 77

27 Proving Screen LOGIN: The CONFIGURATION MENU allows configuration of common options in the system. To access the PROVER MENU touch the Spartan Controls logo in the top right corner of the display. This will bring up 3 optional screens to choose from. LOGIN: The 3 screen choices allow for maintenance (configuration changes), reprinting of tickets or alarm menu. Select the left hand maintenance icon. PROVER MENU: Select the PROVER MENU button. You will see a keyboard menu appear asking for a password. Password is 222. PROVER MENU: The PROVER MENU allows the user to enter the most recent meter factor. The system will maintain the last 12 meter proves in history. The meter factor should always be between and in most cases. Page 27 of 77

28 Historical Tickets LOGIN: The CONFIGURATION MENU allows configuration of common options in the system. To access the HISTORY MENU touch the Spartan Controls logo in the top right corner of the display. This will bring up 3 optional screens to choose from. LOGIN: The 3 screen choices allow for maintenance (configuration changes), reprinting of tickets or alarm menu. Select the left hand maintenance icon. HISTORY MENU: Select the HISTORY MENU button. You will see a keyboard menu appear asking for a password. No Password is Required. HISTORY MENU: The history display past unloading tickets. You can use the up/down arrows to view tickets or enter a specific sequence number. Any ticket in history can be reprinted. NOTE: The system also maintains long term ticket and load data in a flash drive. Page 28 of 77

29 Advanced Menu LOGIN: The CONFIGURATION MENU allows configuration of common options in the system. To access the ADVANCED MENU touch the Spartan Controls logo in the top right corner of the display. This will bring up 3 optional screens to choose from. LOGIN: The 3 screen choices allow for maintenance (configuration changes), reprinting of tickets or alarm menu. Select the left hand maintenance icon. ADVANCED MENU: Select the OPERATOR MENU button. You will see a keyboard menu appear asking for a password. Password is ADVANCED MENU: The advanced menu contains options that should only be made at start up or during service. No changes should be made in this menu under normal operation. Page 29 of 77

30 Alarm Menu LOGIN: The CONFIGURATION MENU allows configuration of common options in the system. To access the ALARM MENU touch the Spartan Controls logo in the top right corner of the display. This will bring up 3 optional screens to choose from. LOGIN: The 3 screen choices allow for maintenance (configuration changes), reprinting of tickets or alarm menu. Select the right hand alarm icon. ALARM MENU: The alarm menu allows for viewing of system alarms. The alarm monitoring can also be enabled or disabled. Page 30 of 77

31 Reprinting Tickets LOGIN: The CONFIGURATION MENU allows configuration of common options in the system. To access the TICKET MENU touch the Spartan Controls logo in the top right corner of the display. This will bring up 3 optional screens to choose from. LOGIN: The 3 screen choices allow for maintenance (configuration changes), reprinting of tickets or alarm menu. Select the middle ticket icon. PRINT TICKET MENU: The historical tickets are displayed. You can use the up/down arrows to view tickets or enter a specific sequence number. Any ticket in history can be reprinted. Page 31 of 77

32 5.5 TUS Software Configuration Using TUSPHD Software INSTALLATION MANUAL INSTALLATION (will work on XP or any PC having an existing VB6.0 application previously installed) 1. Create a folder (TUSPHD) C:\TusWin 2. Copy the files provided by Spartan Controls into the folder: 3. If you have a previous version installed back up the files in the data directory then delete to entire data directory. Overwrite the existing files in directory with the updated files. 4. Run ROCTUSPHD.exe and a sub folder named C:\TusPHD\Data will be created. In the data directory will contain the configuration and history files for the system. Page 32 of 77

33 CONNECTING TO HARDWARE Communications are established between your PC serial port and the ROC LOI serial port. The LOI port must be wired into the CPU card or direct connection to the CPU card is required. Page 33 of 77

34 OPERATION IMPORTANT: The program has a single location and truck database. When you upload you will over write the database file on your PC. When you download you will over write the database in the ROC. It is strongly recommended that you regularly back up your data base files to another location on your PC for future access. Your database records are located in the ROCTUS.MDB file of the TUSPHD data directory. The TUSPHD software can be used for configuration changes, database management and trouble shooting. When starting the program you will have the screen illustrated below. Page 34 of 77

35 A brief out line of the menus are listed in the following table: Config ROC Com settings Connect To ROC Allows for communication changes to ROC Start communications to ROC for data transfer View ROC Ticket History Edit ROC inputs and Clock Upload and viewing of truck tickets Auto Create FDC FDEDATA.DB Configuration of FDC files for accounting program Manual Create FDC FDEDATA.DB Configuration of FDC files for accounting program Browse/Edit FDC Files Configuration of FDC files for accounting program Configure Location MDB Configuration of well database in PC database Configure Truck MDB Configuration of truck database in PC database Data Logger Upload up to 8 truck unload datalogs ERCB Test Cases Allows verification of volume calculations Confirms communication to ROC Edit ROC Locations Viewing & editing of well database in FB107 Edit ROC Trucks Viewing & editing of truck database in FB107 Edit TUS Configuration Main system configuration screen Meter Fault Configuration Allow configuration of fault configuration settings Meter Factor History Historical records of meter proves Run Time Data View data while truck is unloading Exit Exit Program Config ROC Com Settings: This screen allows communication changes in your ROC. Leave settings as default. Page 35 of 77

36 Connect To ROC Change PC Com Settings: This screen allows communication changes in your PC. This will be set up at startup and should not be changed under normal operation. Most common setting is COM , n, 8, 1 View Ticket History Allows viewing and uploading of historical tickets in ROC. You can also set a contract hour for your accounting records. IMPORTANT: The program has a single location and truck database. When you upload you will over write the database file on your PC. ROC Clock Allows viewing of ROC Clock to verify communications to ROC. Page 36 of 77

37 Configure Locations: This screen allows the editing and new location entry. The location entry requires the information illustrated below. Most of the entries are self-explanatory. The minimum and maximum oil densities are the expected limits of density you expect for this location for use when the AutoComp software is enabled. The same entry is required for water densities. NOTE: The Oil Range +/- will automatically update the minimum and maximum oil densities. It is recommended to keep this limit to less than 0.10 value. Page 37 of 77

38 IMPORTANT: The program has a single location and truck database. When you upload you will over write the database file on your PC. When you download you will over write the database in the ROC. It is strongly recommended that you regularly back up your data base files to another location on your PC for future access. Your database records are located in the ROCTUS.MDB file of the TUSPHD data directory. Page 38 of 77

39 Edit ROC Locations Allows viewing and editing of well locations in FB107. Page 39 of 77

40 Configure Trucks: This screen allows the entry of up to 100 trucks. The truck entry requires the information illustrated below. You require a 1 to 4-digit code along with a truck company name. IMPORTANT: The program has a single location and truck database. When you upload you will over write the database file on your PC. When you download you will over write the database in the ROC. It is strongly recommended that you regularly back up your data base files to another location on your PC for future access. Your database records are located in the ROCTUS.MDB file of the TUSPHD data directory. Page 40 of 77

41 View ROC Trucks This screen allows viewing and editing of the trucks in the FB107. Data Logger: This screen allows you to enable data logging of consecutive unload records. The PC has to remain communicating to the ROC for this option as the records will be saved to your hard drive. Page 41 of 77

42 View TUS Configuration: This is the main configuration screen for the system operation. The configuration can also be made using the front keypad per section 5.3 of this manual. The configuration of this screen will likely not change after initial commissioning and startup. The definition of each setting is explained in more detail in section 5.3 of this manual. Release Date Meter Factor BSW Enable BSW Divert BSW Global B Cut Switch Point Delta Density AutoComp Min Flow AC Dens Dev Dry Oil Decide Oil Dielectric Limit Software version Meter Factor entry after proving Cut Monitor installed? 0 = no, 1 = yes Divert water cut for 3 way divert valve See NOTE a Low water cut calibration offset for all wells < 5% water cut only (a change of 10 is approximately 1% water cut) Point where calculation switches from cut monitor to Micro Motion density (Default 4.5) Density stability range for Autocomp Minimum flow for Autocomp calculation Density tolerance decide for AC Water cut limit to accept Autocomp oil calc Low limit dielectric for autocomp calc Page 42 of 77

43 AutoComp Enable Autocomp = 0 off, 1 code, 2 automatic Next Sequence Number Load tracking counter Ticket Copies Printed ticket quantity NoFlo TO Load will terminate if no flow is present past setting 0 = Wet 1 = Dry Wet / dry oil logic 0 = Std 1 = Rev DOUT Discrete Out logic setting Heavy Oil b Trim Density Calculation offset for heavy oil BSW Note a: When the oil goes from wet to dry there is a delay count of approximately 50 seconds before the valve switches. When the oil goes from dry to wet there is a delay count of approximately 5 Seconds. Run Time Data Allows viewing of data during unloading process. Page 43 of 77

44 Meter Factor History Historical records for up to 20 meter factors are maintained by the system. Page 44 of 77

45 ERCB Test Cases The ERCB test case menu allows you to test the calculations being performed by the FB107 system. The calculation tested in the API calculation during dry oil conditions (when water cut is less than configured cut switch point). By selecting the ERCB test case 1-10 an excel file is created in the data directory showing the results of the test as dictated in Directive 17. Page 45 of 77

46 5.6 TUS Software Configuration Using ROCLINK800 System configuration can be done by ROCLINK800 software however the tickets, truck and well database can only be viewed one field at a time. For viewing and editing of the system wells and trucks it is recommended using TUSPHD software. Page 46 of 77

47 6.0 Operation 6.1 Operating the Truck Unload Panel The following provides the truck unloading instruction for the Transloader and Truck Unloading system software. Transloader Unloading Instructions LOGIN: There are 2 selections at LOGIN. If you select the RAILCAR button you can enter is a batch mass & volume for the rail car. If the mass or volume is reached an alarm will be posted on the bottom of the display. To initiate the unloading process touch the LOGIN button. TRUCK CODE: Enter the TRUCK CODE from a predefined numerical list. WELL CODE: Enter the WELL CODE from a predefined numerical list. Page 47 of 77

48 TICKET NUMBER: Enter the truck ticket number and rail car ID number. VERIFY DATA: This screen shows the selections made. If everything is correct touch the NEXT key. If a correction is required touch the BACK key. GROUNDING & ALARMS: The alarms or ground status is displayed on this screen. If there are any alarms or the truck is not grounded you will not be able to proceed. If there are no alarms the screen will proceed to the UNLOAD DATA screen. UNLOAD DATA: The UNLOAD DATA screen displays the process data during the unload process. If you are monitoring the volume or mass for the rail car touch the RAILCAR key to access the totalized values for the rail car. Page 48 of 77

49 RAIL CAR MASS & VOLUME: The RAILCAR screen allows the user to enter the maximum mass and volume for the rail car. After the entered target is reached an alarm indication will be displayed on the screen. You can disable the alarms on this screen if desired. UNLOAD DATA: Touching the BACK key will return you to the UNLOAD DATA screen. LOGOUT: When the truck unload is complete you touch the LOG OUT key. LOGOUT: The final volume and average water cut is displayed. This screen allows you to confirm to STOP unloading or go back to the UNLOAD DATA screen. If you are done touch the STOP key. Page 49 of 77

50 TICKET: The final ticket will be displayed. Touch the PRINTER key to print the ticket. After printing is complete the transaction will be completed and the screen will go back to LOGIN for the next unload. LOAD COMPLETION: After printing is complete the transaction will be completed and the screen will go back to LOGIN for the next unload. Page 50 of 77

51 6.2 Not In Use Page 51 of 77

52 6.3 Historical Unload Data LOGIN: The CONFIGURATION MENU allows configuration of common options in the system. To access the HISTORY MENU touch the Spartan Controls logo in the top right corner of the display. This will bring up 3 optional screens to choose from. LOGIN: The 3 screen choices allow for maintenance (configuration changes), reprinting of tickets or alarm menu. Select the left hand maintenance icon. HISTORY MENU: Select the HISTORY MENU button. You will see a keyboard menu appear asking for a password. No Password is Required. HISTORY MENU: The history display past unloading tickets. You can use the up/down arrows to view tickets or enter a specific sequence number. Any ticket in history can be reprinted. NOTE: The system also maintains long term ticket and load data in a flash drive. Page 52 of 77

53 6.4 Meter Proving Volumetric Proving: This is the preferred method proving a Micro Motion coriolis meter. Use either a Ball Prover or Compact Piston Prover to insure you can prove the normal operating rate of the truck unloading. The transmitter should be configured to provide the prover with 100,000 pulses per 1 m3. The volume pulse from the Micro Motion is non corrected volume. The volume from the Micro Motion also does not account for any previous meter factor entered in the unloading panel. The new meter factor directly replaced the old meter factor in the system. The proving should be done at a constant flow rate close to the normal unloading rate at the facility. The prover will calculate a meter factor based on the formula: Prover Volume / Micro Motion Volume The meter factor can be entered into the system by the driver display, TUSPHD software or ROCLINK software. The following is the Proface display instructions: Proving Screen LOGIN: The CONFIGURATION MENU allows configuration of common options in the system. To access the PROVER MENU touch the Spartan Controls logo in the top right corner of the display. This will bring up 3 optional screens to choose from. LOGIN: The 3 screen choices allow for maintenance (configuration changes), reprinting of tickets or alarm menu. Select the left hand maintenance icon. Page 53 of 77

54 PROVER MENU: Select the PROVER MENU button. You will see a keyboard menu appear asking for a password. Password is 222. PROVER MENU: The PROVER MENU allows the user to enter the most recent meter factor. The system will maintain the last 12 meter proves in history. The meter factor should always be between and in most cases. Page 54 of 77

55 7.0 Appendix 7.1 Modbus Access FB107 ModBus Map As of Version 2.18 Date: APRIL 2011 Default Modbus SOFT POINT 31 TusPhd Page 1 of 2 Start End DATA T L P Meter Flow Rate M3/Minute Flow Density kg/m Flow DegC % Inst Water Cut % Avg Water Cut Load Accumulation M3 at Flow DegC Current Truck Code Current Well Code Day Oil Total M3 at 15C Day Water Total at 15C Day Emulsion Total at 15C Runtime Net Oil M3 at 15C Runtime Net Water M3 at 15C Runtime Flow Minutes Future Runtime Variable Ticket Sequence Number Displayed and Request SeqNum Target YYMMDD HHMM Ticket Truck Code Ticket Well Code SOFT POINT 32 TusPhd Page 2 of 2 DATA T L P Ticket Weigh Bill g/cc Oil at 15C for NOC g/cc Water at 15C for NOC Flow Weighted Avg DegC for Load % Water Cut at 15C Load Oil M3 at 15C Load Water M3 at 15C Normal Load M3 at 15C Flow Weighted Avg kg/m Auto Comp Oil g/cc Auto Comp Water g/cc Auto Comp % water Cut Page 55 of 77

56 Flow Minutes for Load Shrinkage Dry Tank M3 at 15C Wet Tank M3 at 15C Load KiloGrams Future Ticket Parameter Future Ticket Parameter Future Ticket Parameter 7.2 Communication Wiring The communication wiring to the FB107 panel is illustrated below. There is also an additional combination port (LOI port) not illustrated. The LOI port is used for configuration with the ROCLINK and TUSWIN program. 7.3 Water Cut Measurement Spartan Controls Water Cut Offerings The system water cut determination is typically provided in the following methods: 0-5% Density Compensated Drexelbrook Cut Monitor 0%-100% or 5%-100% Net Oil Density Comparison using Micro Motion Page 56 of 77

57 0%-100% Microwave water analysis using Phase Dynamics Most systems incorporate the Density Compensated (Spartan U.S. Patent: 5,325,066, Canadian Patent # 2,074,017) 0-5% monitor and the Net Oil Density Comparison (U.S. patents# 4,689,989, 4,773,257) 5%-100% for the water cut calculation. The density compensated water cut monitor is used to improve WC resolution to pipeline spec over the 0-5% WC range. In heavy oil applications >930Kg/M3 it is beneficial to perform the 0-100% WC calculation using a Phase Dynamics Microwave Analyzer. The Micro Wave analyzer does not require a minimum oil/water density span in the calculation allowing it to provide significantly improved WC accuracy. In applications where minimal data base management is desired the Phase Dynamics can be used across density ranges from condensate to heavy oil. In these applications the Density Compensated (Spartan U.S. Patent: 5,325,066, Canadian Patent # 2,074,017) is implemented to fine tune the water cut measurements due to density effects. MEASUREMENT HARDWARE Micro Motion Coriolis Meter Drexelbrook Water Monitor Phase Dynamics Water Analyzer Custody Transfer Approved No Maintenance Required Measurements Provided: Volume Density Temperature Provides Measurement for 0-100% Water Cut Calculation in Conventional Oil Applications. Digital Calibration No Maintenace Probe Design Provides Measurement for High Resolution 0-5% Water Cut Calculation in Conventional Oil Applications. When combined with a Coriolis meter the water cut ranges are: Drexelbrook 0-5% water cut Coriolis Meter 5-100% water cut. Digital Calibration No Maintenace Design Provides Measurement for 0-100% Water Cut Calculation in Heavy Oil Applications. Page 57 of 77

58 7.4 Not in Use 7.5 Autocomp Software Water Cut Background Most Truck Unloading applications implement water cut calculations based on oil & water density comparisons. The following illustrates the method. Density Inferred Water Cut (0-100%) Water cut measurement in the range of 0% to 100% is achieved using the density signal from the Coriolis meter. The on line density signal is compared against dry oil and clean water densities that were previously programmed in the flow computer. Water cut measurement using density is achieved as follows: Xw = m o w o m = Density Mixture (Measured) w = Density Water (Entered) o = Density Oil (Entered) Xw = Water Cut Measured / Calculated The calculated volume split of oil and water is temperature corrected to 15C. The following example illustrates the calculation. 100% 100% Water Cut 60% Water Cut 54.4% 0% 0% Density (Kg/M3) Density (Kg/M3) This comparison results in a straight-line relationship to calculate percent water cut. Generally the maximum achievable water cut accuracy is +/-1%. Oil & water density spans less than 100Kg/M3 will result in decreased water cut accuracy. The key to an accurate water cut measurement is maintaining accurate oil & water densities in the system database. The calculation is only as good as the data provided for the calculation to take place. Page 58 of 77

59 7.6 Reserved Soft Points Soft Point 1 in the FB107 is used for Micro Motion variable coming in by modbus SP1 DATA 1 Mass Flow Rate DATA 2 Density DATA 3 Temperature DATA 4 Volume Flow Rate DATA 5 Viscosity DATA 6 Pressure DATA 7 Mass Total DATA 8 Volume Total DATA 9 Mass Inventory DATA 10 Volume Inventory DATA 11 Raw Tube Frequency DATA 12 Left Pick Off DATA 13 Right Pick Off DATA 14 Drive Gain Soft Point 11 in the FB107 is used for Phase Dynamics variables coming in by modbus SP 11 DATA 1: PDI CUT via Modbus DATA 2: PDI Process Temperature via Modbus DATA 3: PDI User Temperature via Modbus DATA 4: PDI Emulsion Phase via Modbus DATA 5: PDI Oil Adjust from TLP 22,0,63 User Configured DATA 6: PDI Water Cut Offset TLP 22,0,64 User Configured DATA 7: RawCut = PdiCut - PdiWCoffset DATA 8: Density Used for Corrected Water Cut DATA 9: Corrected Water Cut % not Zero Clipped DATA10: Corrected Water Cut (%/100.0) and Zero Clipped. DATA11: Flow Density g/cc DATA12: VCF DATA13: Location Oil Density g/cc DATA14: PDI Slope via TLP 22,0,65 User Configured Page 59 of 77

60 SOFT POINT 31 DATA T L P Meter Flow Rate M3/Minute Flow Density kg/m Flow DegC % Inst Water Cut % Avg Water Cut Load Accumulation M3 at Flow DegC Current Truck Code Current Well Code Day Oil Total M3 at 15C Day Water Total at 15C Day Emulsion Total at 15C Runtime Net Oil M3 at 15C Runtime Net Water M3 at 15C Runtime Flow Minutes Future Runtime Variable Ticket Sequence Number YYMMDD HHMM Ticket Truck Code Ticket Well Code SOFT POINT 32 DATA T L P Ticket Weigh Bill g/cc Oil at 15C for NOC g/cc Water at 15C for NOC Flow Weighted Avg DegC for Load % Water Cut at 15C Load Oil M3 at 15C Load Water M3 at 15C Normal Load M3 at 15C Flow Weighted Avg kg/m Auto Comp Oil g/cc Auto Comp Water g/cc Auto Comp % water Cut Flow Minutes for Load Shrinkage Dry Tank M3 at 15C Wet Tank M3 at 15C Load KiloGrams Page 60 of 77

61 Future Ticket Parameter Future Ticket Parameter Future Ticket Parameter 7.7 TROUBLESHOOTING This section is useful for solving some common problems that may occur. If the information does not solve the problem call Spartan Controls service (780) TUSPHD Troubleshooting Micro Motion and Phase Dynamics data can be viewed from the ROC Clock screen in TUSPHD as shown. Page 61 of 77

62 Run Time Data The unloading data can be viewed using the Run Time Data screen in TUSWIN 7.8 Not in Use Page 62 of 77

63 7.9 AIR ELIMINATOR TO SPILL BOX OR VAPOR RECOVERY CUSTOMER RESPONSIBLE FOR VENT LOCATION DECISION AND TIE IN Air Eliminator Operation OPEN TO VENT ASCO Solenoid CLOSED ASCO Solenoid Drexelbrook PT Level Switch Drexelbrook PT Level Switch Air & Liquid In Liquid Out Liquid In Liquid Out When liquid level in Air Eliminator drops due to in coming gas the level switch opens the vent valve on top of the air eliminator. When liquid level rises to the level switch the vent valve is closed and liquid is pressurized though the metering skid. SPARTAN CONTROLS 7.10 Not in Use Page 63 of 77

64 7.11 Data Logger: This screen allows you to enable data logging of consecutive unload records. The PC has to remain communicating to the ROC for this option as the records will be saved to your hard drive. Data Log Overview The following illustrates the data log information available from the system. The data is broken into 3 portions for illustration purposes. Page 64 of 77

65 Data portion 1 of 3 LogNum Data log number VolRate Volume flow rate in M3/min RawAcc Accumulated uncorrected volume G/CC Density at operating temperature DegC Operating temperature RawBsw Non density corrected BS&W reading (only valid for water cuts in range of 0-5%) BswCut Density corrected BS&W reading (only valid for water cuts in range of 0-5%) UseBsw Decision if BS&W is to be used for water cut NocCut NOC calculated water cut using existing data base O/W densities UseNoc Decision if NOC is to be used for water cut O/W Indicator is system is measuring Oil or Water CutVal Water cut being reported by system (no Autocomp) Page 65 of 77

66 Data portion 2 of 3 fwcf NetWat fctl NetOil fkpa fcpl OilDen WatDen BswCutA UseBsw NocCutA UseNoc O/W Water correction factor for temperature Net accumulated water Oil correction factor for temperature Net accumulated oil Pressure at standard conditions Pressure correction factor Oil Density from database Water density from database AC BS&W Confirmation to use BS&W AC water cut reading Confirmation to use NOC calculation Indicator is system is measuring Oil or Water Page 66 of 77

67 Data portion 3 of 3 CutValA fwcfa NetWatA fctla NetOilA OilDenA WatDenA NetTtl NettlA NetCut NetCutA AC water cut reading AC water correction factor for temperature Net accumulated AC water AC oil correction factor for temperature Net accumulated AC oil AC oil density AC water density Net accumulated liquid Net accumulated AC liquid Ave water cut without AC Ave water cut with AC Page 67 of 77

68 7.12 FB107 TUS Startup Procedure 1) GETTING READY The following devices will need site configuration: Drexelbrook Cut Monitor Micro Motion Meter Truck Unloading Panel You will need software: ROCLINK for Windows ROC TUSWIN Drexelbrook HARTWIN CM3 spread sheet Micro Motion Prolink 2 You will need a ROC com cable and a HART modem for the above programs. There may also be Valves, Air Eliminator and a Ground Fault Permissive to set up. 2) Micro Motion Commissioning With the Micro Motion meter properly installed and wired you will need to complete the following steps using Prolink software: Configure outputs Frequency VOL (100,000p/M3) for proving Configure density slug flow limit 0.5g/cc Configure 485 port 19,200 None 8 1 With meter full of liquid and blocked in perform Zero Flow Calibration Page 68 of 77

69 3) Drexelbrook Commissioning With the Drexelbrook properly installed and wired you will need to complete the following steps using HARTWIN software and the CM3 spread sheet: - Calculate Zero & Span using CM3 spread sheet. Ask site what are the expected min and max oil densities. Include 50Kg/m3 beyond there numbers. Typical entry is illustrated. - Scale the Drexelbrook for Capacitance values and the ROC for the Dielectric values. You may need to bypass the Drexelbrook I.S. barrier located in the panel when communicating with HARTWIN. Final calibration is completed later. 4) CONFIGURE DREXELBROOK Configure Drexelbrook as per illustration -Set Analog Loop Assignment to LEVEL -Set Dampening to 0 -Set Level Units to INCHES -Set Maximum level to 100 -Set LRV to 0 Set URV to 10 -Set zero and span capacitance per your spread sheet -Set Lower Level = 0 -Set Upper Level = 10 Write to Transmitter Page 69 of 77

70 5) TUS SOFTWARE INSTALL Required for panel software is ROCLINK for windows and TUSPHD software. Communications are made through the LOI port of the FB107 using a standard ROC communications cable. 6) DOWNLOAD USER PROGRAMS Download new user programs into FB107 using ROCLINK. 7) CONFIGURE ROC Refer to the FB107 manual. Basics are: Set CPU Clock Speed to MHz Set Display Port Owner as ROC/MODBUS Slave Turn off AGA s Turn off PID s Turn off History Configure AI s RTD Input enable if using an RTD AI-2 Dielectric (from #4 record) COM 1 = 19200, N, 8, 1 Write to EEPROM (Flags) Page 70 of 77

71 8) CLEAR PROGRAM MEMORY Using MAP or Proface display Initialize the database in the 107. Access Initialize in Menu 2 (Shift 5 accesses menu 2) 9) CREATE DATABASE Using the latest version of TUSPHD Create the Location data into the TUSPHD database. Edit the Oil Range and oil / water limits as required. Note on limits: High Water = 1.2 Low Oil = 0.6 will always perform Autocomp. Download the records to the ROC. 10) CREATE TRUCK DBASE Using the latest version of TUSPHD create the Truck data into the TUSPHD database. Download the records to the 107. Page 71 of 77

72 11) EDIT CONFIGURATION Using TUSWIN edit TUS Configuration as required. 12) SET UP AIR ELIMINATOR 13) TEST VALVE OPERATION 14) CALIBRATE DREXELBROOK The Drexelbrook should be calibrated with a clean truck of oil running through the system. Perform the following procedure while communicating to the Drexelbrook: -Start an unload -Take oil sample and confirm cut -Go to Z screen on MAP ( Shift Z ) -If Kmix < Koil raise your Drexelbrook Z & S numbers until Kmix > than Koil and your water cut is within 1% of spun cut. Example: If Kmix = 2.2 & Koil =2.3 If Drex CZ = 28pF & CZ = 38pF Raise CZ to 29pF and CZ to 39pF and re check, Keep the same spread between the Z&S values. In this example the spread is Flow rate Water Cut Kmix B trim Emul dens Oil dens Koil T trim Page 72 of 77

73 39 29 = 10 pf While unloading dry oil record water cut reading while taking an oil sample. Adjust Global B trim to match your spun cut. If any individual well reads incorrect in the range of 0-5% water cut you can use the Location B trim to adjust. 15) PRINT WELL & TRUCK LIST A well & truck list should be printed and posted at the panel for the driver s reference. The list can be printed at the unloading panel. Refer to Section 5.4 for printing instructions. Page 73 of 77

74 7.13 Volume Calculation Test Case 7.14 Not in Use 7.15 Not in Use Page 74 of 77

75 7.16 Totalized Flow Options The system has the option to print volume totals as follows: 0 Standard Volume Totals (Oil, Water & Emulsion per unload) 1 Wet & Dry Tank Volumes per divert valve operation (per unload) 2 Daily Volume 15C 3 All Volumes listed in 0 2 options The ticket will always include oil volume, water volume and emulsion volume as listed in option 0. The other options will add required totals to the ticket as desired. The following illustrates the 4 ticket options: Configure Using TUS Configuration Screen: Page 75 of 77

76 Code 0 Ticket Code 1 Ticket Page 76 of 77

77 Code 2 Ticket Code 3 Ticket Page 77 of 77